Building construction



Dec. 19, 1939. s. s. cALAFATl BUILDING CONSTRUCTION Filed March 5, 1935' 5 Sheets-Sheet 1 /EEL 8 13 Ivm-og- 5. Cmnmw INVENTOR.

ATTORNEY.

S. S. CALAFATI BUILDING CONSTRUCTION Dec. 19, 1939.

5 Sheets-Sheet 2 Filed March 5. 1935 Farr l INVENTOR.

ATTORNEY D@- 19, 1939- s. s. cALAFATl 2,184,113

ABUn-DING CONSTRUCTION Filed arch 5. 1935 5 Sheets-Sheet 4 ma va ra/z 6. C nl 11F/7 7'/ I NVEN TOR.

ATTORNEY.

Dee.. 19,1939. s s cALAFAT, 2,184,113

BUILDING CONSTRUCTION Filed March 5, 1955 5 Shee'ts-Sheet 5 lINVENTOR.

BY l/Lf.

ATTORNEY,

Patented Dec. 19, 1939 UNITED STATES PATENT OFFICE BUILDING CONSTRUCTION Salvator S. Calafati, New York, N. Y., assgnor of four-fifths to Annunziata Calafati and oneiith to John M. Cole, both of New York, N. Y.

Application March 5, 1935, Serial No. 9,436

16 Claims.

The present invention relates to building construction and is more particularly directed toward improvements in buil ding construction whereby the floors, ceilings, Walls, and roofs, or any of these, may employ preformed cellular metal form panels to cover extended areas. The assembled units provide smooth surfaces at top and bottom for the reception of floor, Wall and ceiling finishes, and roong material.

To achieve these advantages, the invention contemplates that the sheet metal shall be formed to provide a comparatively narrow flat area of unit width (for example six inches) and two converging diagonal elements which meet opposite the center line of the flat area to form a cell of triangular cross section.

At the apex of the triangle the material is bent laterally into a plane parallel with area and extended in a This flange may form the plane of the rst flat flange to the right or left. a part of-an adjacent cell of a multiple celled unit, or may be adapted for connection with a sim unit. For the former equals to the unit forms an area of unit ilar flange of an adjacent purpose the ange width width, while for the latter purpose the flange extends part way,

connection to be made with the If it extends the unit width, it

depending width similar to that on the other face. The metal is then bent back to form a reversed cell of triangular cross section, the diagonal element meeting the adjacent edge of the first unit area. The metal is then bent in to the plane of rst flat area to extend the exposed surface another unit width.

It is again bent to form another diagonal element and triangular cell similar to the rst cell. The

formation of these cells may continue, or the edge of the flange formed into some convenient shape for joining to an adjacent shape or unit. The joints or seams formed where the diagonal elements of a unit meet alignment and preven The cells formed in may be welded to assure t separation. this way utilize the metal in a very efficient manner so that great strength and little deflection may be had with `minimum depth of section.

When a plurality of the preformed units, of single or multiple width, are placed side by side, 5 the seams formed by the meeting of the diagonal elements and the narrow flanges of the adjacent units may be interlocked, welded together, secured together by sliclable clips forced over inwardly bent flanges, or a filler may be utilized.

Owing to the inherent rigidity of the parts having alternating units with opposed angles, the provision of a continuous flat surface on both faces of the units and of areas made up on a plurality of the units, and the possibility of securing the units together as described, an exceedingly strong, rigid inflexible panel smooth on both sides may be provided for floor, wall, ceiling, or roof'. Not only is it of less weight and thickness than conventional constructions designed for some of these purposes, but additional advantages are available; such as, ease of fireproofing, insulating, sound deadening, and application of wall finish, freedom of shrinkage, warping and the like, and saving in building height (without sacrifice of room height).

The availability of units, of the elementary shape above referred to, also makes it possible to slightly alter them where desired so that heating, Ventilating, and/ or air conditioning may be accomplished by using the cells as ducts to convey the air to and from the rooms, thereby making it unnecessary to build into the walls and floor, Ventilating ducts, registers, and the like. l

The accompanying drawings show for purposes of illustration, several forms of* cellular metal building units, and the construction of floors, walls, ceilings, and roofsv from the same, it being understood that the drawings are illustrative of the invention and that they do not limit the same.

In these drawings:

Fig. 1 is a sectional view showing a single cell unit and a multiple cell unit secured together, the thickness of the metal being exaggerated.

Fig. 2 is a sectional view showing one form of reinforcing which may be used with the cellular structure of Figure 1;

Fig. 3 is a sectional view showing another form of reinforcing which may be employed;

Figs. 4, 5 and 6 are sectional `views through modified forms of cell construction;

Fig. l"I is a fragmentary section showing a building showing system illustrating modified construction for gether;

Fig. 8 is an elevational view of a building wall made up of a plurality of the units and showing gable, window, and door openings Fig. 9 is a perspective view with parts in section to show the assembly of floor, wall, ceiling and roof from panels employing the units of the preceding figures;

Fig. 10 is a sectional detail showing roof construction;

Fig. 11 is a perspective view, with parts in section illustrating the formation of the ridge of a roof, and a connection of the roof and gable wall;

Fig. 12 is a top plan view illustrating a hip;

Fig. 13 is a perspective view of a fragment of a foundation, floors and walls;

Fig. 14 is a perspective view of an anchorage for use in a brick wall to support a floor;

Fig. 15 is a diagrammatic sectional view through a floor showing a wall in elevation and indicating the paths of air for heating and Ventilating;

Fig. 16 is a front elevational view of one form of insert to be used in a cell to block off a plurality of cells of the wall and floor system;

Fig. 17 is a front elevational view of a form of insert intended to block or close off a sirgle horizontal cell and single vertical cell of .the type having the apices of the triangular cells together;

Fig. 18 is a perspective view of the member shown in Figure 17;

Fig. 19 is a perspective view of a floor and wall the adaption of the same for heating and Ventilating; and

Fig. 20 is an elevational view showing the connection between the floor system and a furnace and air conditioning plant.

In Fig. 1, a single celled unit is shown at I0. It has a face vIlla of unit width, two diagonal elements Ib and Illc (which meet along a seam Id), and lateral extensions or flanges Ille and Illf terminating in inwardly extending anges Ing and Illh. The seam Iild may be welded at the factory, if desired. The combined width of the extensions I 0e and I 0f equals the width of the face Illa and these extensions together form a face |012 In Fig. 1, the multiple celled unit is shown at I I. Ithas two faces I Ia and I Ia' of unit width on the bottom and one such face Ila on the top, four diagonals IIb, IIc, lid, and IIe, and two lateral extensions Ilf and Iig, similar to the extensions I 0e and I0f of unit I0, and provided with similar flanges IIh, and IIz'. 'I'he seams IIld, IIJ', lik, and I Im may be welded at the factory, if desired and ground smooth.

The flanges Illh and Ilh are secured together by a slidable clip I2 which ts these flanges and holds the extensions together.. The units I0 and II abut along seams indicated at I3 and I 4 and these seams may be welded after installation.

The diagonal elements are preferably of the same width, and at an angle in the neighborhood of 45 to the plane of the flat face 0f the unit. 'Ihis brings them together at approximately right angles to one another along the seams. The units are then symmetrical and may be used upside down or turned end for end. With the units at 45, the depth of the unit is then one-half the width of the single celled unit. While with an angle 0f approximately 52, the depth of the section is about two-thirds the unit width.

While units of varying load carrying capacity may be made by varying the gage of the metal joining two units toused and/or the depth of the section, it is ysometimes desirable to reinforce certain of the cells to carry extra loads, without changing the basic unit at all. Fig. 2 shows one way of doing this for lighter loads. Stiifeners 20 are inserted so as to lie adjacent a pair of converging diagonal elements. These stiffeners have flanges 20a to fit against the flat face of the units and flanges 2Gb to t against the adjacent diagonal elements.

Fig. 3 shows a stronger form of reinforcing. Here angle irons 2| are inserted in alternate cells to supplement the diagonals and corrugated plates 22 are inserted into the intermediate cells to supplement the flat areas. The angle irons bridge the clips I2 as indicated in the drawings. The center corrugation 22a of plate 22 bridges the clips when these plates are inserted in cells formed by uniting two units.

The cross section .of unit 23 of F'gure 4 is the same as that of unit Ill except that one of the extensions 23e, corresponding with either extension Ine or Inf, is of one-half the effective width of the other extension and has a 45 flange 23f parallel with the adjacent diagonal element. This form of unit is particularly designed for use in the erection of outside or inside corners where one wall is at 90 to the other wall indicated by the second similar unit shown in dotted lines. It compensates for the wall thickness at the corner.

The unit 24 shown in Fig. 5 is modified on the right of the line 24a so that the entire unit is A the Width of the standard unit. The unit 24 is designed for welding against another flat wall, and compensates for wall thickness.

Fig. 6 shows two cellular units 25 of modiiled form secured together. The laterally extending flanges 25a and 25h are narrower than the flanges shown in Figures 1-3, and are provided with upwardly opening grooves 25e, 25d. When the two units 25 are brought together, they can be inside welded as indicated at 25j, the welding being done fromi above, instead of from below. This provides a smoother outer surface. and permits the insertion of a pipe, conduit or the like, 25g. A filler plate 25h has flanges 25m, 25u which t into grooves 25e, 25d so as to complete the cell, and provide a smooth upper surface. This flller may be welded in place. As shown in Figure 6, the cells have short perpendicular walls 25p between the flat faces and diagonals to provide greater inter-cell bearing area.

Where curved structures, such as walls for grain bins, silos, coal pockets, tanks, roof or railway cars, and the like, are desired the units may be designed so that, when assembled, a cylindrical surface results. In the form shown in Figure 6, this may be obtained by using a wider or a narrower filler strip 25h. The wider strip will shift the right hand unit down toward the dotted line position.

In Fig. 7, the right hand edge of one of the units is shown as having groove 26a, while the lefthand edge of the adjacent unit has a curved flange 26h which is adapted to be received in the groove, either by swinging this part from the dotted to the full line position, or by a suitable press. This arrangement takes the place of the slidable clip I2, or the filler 25g and the interlocking parts may be welded or not as desired.

Figure 8 illustrates the assembly of the side wall of a house. Single width units I0 and double width units II of random lengths are utilized to provide the window and .door openings and gables. A oor slab would be assembled in the same way. The ends 21 and longitudinal joints 28 are united to form a monolithic slab which includes the door and window frames. Oxyacetylene welding, spot welding, arc welding or-some form of interlocking of joints may be utilized.

Figure 9 shows a perspective view of a building employing the welded sheet metal unit shown in Fig. 1, although it will be understood that the units shown in Figs. 2, 3, 6, or '1 may be used. The sill 30 and plate 3| ,are each made of two sheet metal angles welded together, the angles 30a and 3|a being plain angles with equal flanges and the angles 30h and 3 Ib having a doubled fold 30D and 3|b. The angles are spot welded together as indicated at 30'. The end of the floor 32, formed of units I and is inserted in the laterally opening channel 33, formed by the sill angles 30a and 30h. It may be welded in place by flame or arc welding, or spot welded at34, the tools being inserted through holes 35, or through the opening between the flanges 25d and 25o, of Figure 6. The lower end of the wall 36, also formed of units l0 and is inserted in the upwardly opening channel 31, formed by the sill angles 30a and 30h. It may be welded to both sill angles, as indicated at 38. The holes 39 formed in the wall member as well as the holes 35 in the floor member will be closed by the wall and floor surfacing. The sill member 30h has triangular holes 30e punched in its upper wall to match the cells of the wall member 36 so that the wall member may be connected into the sill to form a conduit for heating and Ventilating. The air connection may be direct to the floor unit, or if this is closed off, connection may be had through holes 30d in the bottom of the sill to a duct. AHoles 40 may be punched in the diagonals near the holes 30 to facilitate the passage of wires, pipes, etc. These holes do not materially affect the strength of the structure, the loads being distributed throughout all the metal. Instead of welding, rivets 4| may be employed.

The second floor indicated at 42, may be like the iirst oor. It is received in a channel member 43 formed of sheet metal to have two doubled walls 43a and 43h spaced to form a channel. The

' the side edges ofthe Afloor slab or may be used to receive the upper or lower ends of a wall slab.

The plate 3| is secured on the upper end of the wall as shown (in Figs. 9 and 10) and the next oor (or ceiling) fastened in as indicated. Plate angle 3 b may have holes such as 30e or not,

4as desired. Short angles 66 are welded to the top of the plate, and a roof slab 41 welded to these angles. The roof slab may also be made up of units of such as l0 and Figure also shows the placing of ceiling and wall nish, 48, 00, outside wall covering 50, and

roofing 5l, on the at surfaces provided by the cellular units. For these purposes one may use, as indicated elsewhere in the drawings, other nishes or a decorative covering.

In the'arrangement shown in Figure 11, the wall is formed out of elements I0 of single unit width and different lengths, or cut 01T elements l of double width, having a short cell and a long cell so as to produce a stepped eifect as shown in Figure 8 or 11. If the lengths of material for forming this stepped effect is not available, the slab may be trimmed to a suitable shape by a torch. The upper ends 55 ofthe roof members 41 are rested on and preferably welded to a transverse support, such as indicated at 56. The gaps between the upper ends of the roof units are closed by an angle 51. The space above the wall is closed off by a strip 58 welded in place. This strip is preferably L shaped to accommodate the roofing material, and supports a molding 59 adapted to extend down onto the wall members and be welded to the same. It will be apparent that the foregoing provides an exceedingly rigid structure.

In Figure 12 roof forming units 41 are shown as meeting along a hip 60. The joint is covered by a member indicated at 6|, and a similarly shaped angle plate is employed underneath. When these parts are welded together a rigid hip construction is provided.

In Figure 13 a portion of a brick wall is illustrated at 62, and a column or other support at 63. Anchor plates such as shown at 64 are embedded in the wall or column to provide an inwardly projecting support or shelf 65 to support a floor.

The floor supporting system is indicated at 66. It comprises lengths of cell members 61 and 68 supported from the shelves 65. Where certain of the members extend at right angles to the adjacent members a support, such as an I beam 69, may be employed under the joint. The wall 10 may be constructed as indicated in Figure 9 and support an upper floor system as shown at 1 I. A portion of this floor system is reinforced as indicated at 12 to support a partition 13.

Any suitable form of floor finish may be employed; In the drawings, a layer of mastic is shown at 14, and of insulation at 15. Parquet flooring 16 may be placed on mastic 11. The Wall and ceiling nishes may be whatever is desired. Lighting fixtures are indicated at 18, the wiring 19 being carried in the cell members forming the wall or floor. A register is shown at 80.

Figure 14 is anenlarged fragment of wall plate .64, with oblong holes along the'edge and prongs to anchor same to wall. Holes 8| are for the purpose of fastening floor slab by means of screw nails or bolts, prongs 82 are punched from plate and will engage in joints of brick work.

Heating and ventlating The adaptation of cellular wall and floor construction for heating and Ventilating is illustrated in Figures to 20 inclusive. A floor system is diagrammatically illustrated at |00. It is connected to two ducts |0| and |02 for supplying heated air from furnace or for use in withdrawing air from the room for air conditioning. The duct |0| is connected through the bottom of a downwardly facing triangular cell |03. The diagonal members forming this cell are provided with openings as indicated at |04 so that the air may spread out and pass toward the wall through the two adjacent cells |05 and |06. As shown in Figure 15 this air passes into a number of vertically extending cells |01, |01a, |01b, |01c, and |01d, and this air passes out through the register such as that shown at |08, the same being similar to register 80 shown in Figure 13. The air flowing to the right through the cells |03, |05 and |06, and up into the cells |01a, |011), |01c, and 01d, is prevented from passing lengthwise of the sill forming member and into other floor and wall cells by batts, blocks, or stoppers |09 and I0 placed in the sill.

nected to vertical cells H5, IIB, and so that the air passes up or down as desired. The batt H separates the air streams supplied by the ducts |0| and |02 and the batt ||8 stops the sill to the left oi the duct formed by the cells il I,

||3 and Ill.

'I'he batts |09 and ||8 are alike except that one is made right-hand and the other left-hand. 'Ihey have a square cross section as indicated at the lower end' of Figure 19 and are madeof the proper size to iit in the space below the upper sill forming member 30 and inside the ends of the floor forming cells as will be apparent. One end of the batt is provided with a bevelled surface as indicated at ||9 so as not to impede ow of air into the vertical cell.

The batt ||0 shown in Figures 17 and 18 has a rectangular bottom face |20 and a rectangular rear face |2| adapted to rest against the bottom and inner Walls of the sill forming member. It has a triangular upper face |22 adapted to close oif the opening 30e in the upper sill forming plate. The batt has triangular front face |23 adapted to close oi the opening in the cell |24 (this being the cell between the cells and I4). The faces |25 and |26 are bevelled to allow the air to spread and reach the vertical cells |0'|a and respectively. A

The furnace and air conditioner shown in Figure 20 is arranged so that three outlet pipes |30, |3| and |32 lead into the floor, the pipe |32 being connected to a series of cells running at right angle to cells to which the pipes |30 and IBI are connected. A return connection is shown at |33 for the air conditioning.

Any of the cells which are not to be used for heating or Ventilating may be closed up by blowing in suitable packing material or need not to be lled. The batts are inserted andl secured in place in any suitable way before the wall or floor forming members are assembled with cell.

It will of course, be understood that various other expedients may be employed to close oil vertical and horizontal cellsthrough which it is not desired to have the air passed whereby the air duct may comprise selected horizontal cells and selected vertical cells, communication being had through a portion of the cell. The cells in the vertical wall may be closed off from above so that the heating is passed out through the register, or

these cells may be left open so that the airis conducted through either a ceiling register above to the second floor.

This form of heating has many advantages, particularly in that there is no outlay for piping or ducts other than those. necessary in the basement. All the other ducts may be provided for in the floor and wall. A further advantage is that any number of floor units may be connected together by a suitable manifold so that large areas of the oor or the wall may be connected to the furnace or air conditioner. In this way it is possible to provide comparatively large areas to radiating surfaces and maintain the same at the desired temperature so that heat is radiated to the occupants without necessarily overheating the air in the room.

What is claimed is:

1. A structural member for building walls, floors and the like, comprising a single piece of `longitudinally bent sheet metal of indefinite length and uniform cross section. said cross section comprising the base and'sides of a triangle to provide a longitudinally extending cell of triangular cross section, the piece of metal having outwardly bent extensions at the apex of the triangle parallel with the base, whereby the structural' member has two parallel opposed faces and interconnecting diagonal elements, the contiguous parts of the member being welded together along the apex of the triangle to prevent spreading and insure alignment..

2. A structural unit as claimed in claim 1,

. wherein at least one of the outwardly bent extensions is provided with a flange extending toward the opposite face.

3. A structural unit as claimed in claim 1, wherein at least one of the outwardly bent extensions is provided with a flange extending toward and disposed opposite the edge of the opposite face.

4. A structural member for building walls, floors and the like, comprising a single piece of longitudinally bent sheet 'metal of indefinite length and uniform cross section, said cross section comprising the base and sides of a triangle to provide a longitudinally extending cell of triangular cross-section, the piece of the metal having outwardly bent elements at the apex of the triangle parallel with the base of the triangle and of width equal to said base, inwardly bent elements at the extremities of the outwardly bent elements, said inwardly bent elements being parallel with the sides of said triangle and extending to the base of the iirst triangle to form two additional similar but inverted triangular cells, outwardlybent extensions at the apices of said additional triangular cells, whereby the structural member has two parallel opposed faces with interconnecting diagonal elements, the contiguous parts of the member being welded together along the apices of the triangles to prevent spreading and insure alignment.

5. A structural member as claimed in claim 4, wherein said outwardly bent extensions are provided with flanges extending toward the opposite face.

6. In a building floor, wall, or the like, a panel comprising a plurality of sheet metal strips folded along parallel longitudinally extending lines to form units having longitudinally extending cells of trianguar cross section, said triangular cells having bases in parallel planes to form plane surfaces for the opposite faces of the units, the seams formed by the adjacent bases being welded and adjacent units being secured together, the edges of the strips forming the units being in the same face of the panel and opposite the edge of the other face of the same unit.

7. In a building oor, wall, or the like, a panel comprising a plurality of sheet metal strips folded along parallel' longitudinally extending lines to form units having longitudinally extending cells of triangular cross section, said triangular cells having bases in parallel planes to form plane surfaces for the opposite faces of the units, the seams formed by adjacent bases being welded and adjacent units being secured together, and interiorly disposed clips receiving the adjacent edges of the strips for holding the units together.

8. In a building fioorwall, or the like, a panel comprising a plurality of sheet metal strips folded along parallel longitudinally extending lines to form units having longitudinally extending cells of triangular cross section, said triangular cells second being in the having bases in parallel planes to form plane surfaces for the opposite faces of the units, and equal sides in diagonal planes, the longitudinally extending seams of each unit being welded, the edges of the strips forming the units being in one face of the panel so that the other face is comprised entirely of the bases of the triangles, the seams formed by abutting bases of the triangles of adjacent units being welded, the edges of the strips forming adjacent units being spaced, and filler strips secured to said edges.

9. In a building, a. floor panel comprising sheet metal folded to form reversed triangular cells with walls of single thickness, the bases of the cells forming parallel spaced faces having longitudinally extending seams, the seams being welded together, a sheet metal sill having a lateral opening into which the end of floor panel extends and into which the cells open, a wall panel similar to the floor panel and arranged with the cells vertical, the sill having an upper opening to, receive the wall panel.

10. In a building, a oor panel comprising sheet metal folded to form reversed triangular cells with walls of single thickness, the bases of the cells forming parallel spaced faces having longitudinally extending seams, the seams being welded together, a wall panel similar to the floor panel and arranged with the `cells vertical, and a channel shaped member welded to the inner side face of the wall panel and receiving the iloor panel.

11. In a building, a floor panel comprising sheet metal folded to form reversed triangular cells with walls of single thickness, the bases of the cells forming parallel spaced faces having longitudinally extending seams. the seams being welded together, a wall panel similar to the floor panel and arranged with the cells vertical, and a channel shaped member welded to the inner side face of the wall panel and receiving the floor panel, the cells in the floor panel opening into the channel, the wall panel and channel being apertured to provide communication between the cells of the floor and wall panels.

12. In a building, a member adapted to form a sill or plate, comprising two sheet metal members of uniform cross section secured together, the first member being in the form of an angle having a vertical wall and a horizontal wall, the form of an angle having a vertical wall narrower than the vertical wall of the first member and a horizontal wall spaced from the horizontal wail of the first member to form a laterally open channel, the horizontal wall of the second member carrying a vertical ange opposite the projecting portion of the vertical wall of the first member to form a vertically open channel.

13. In a building, a member adapted to form a I sill or plate, comprising two sheet metal members of uniform cross section secured together, the first member being in the form of an angle having a vertical Wall and a horizontal wall, the second being in the form of an angle having a vertical wall narrowerthan the vertical wall of the first member and a horizontal wall spaced from the horizontal wall of the first member to form a laterally open channel, the horizontal wall of the second member carrying a vertical ange opposite the projecting portion of the vertical wall of the flrst member to form a vertically open channel, a horizontal iloor or ceiling forming panel comprising sheet metal folded to form reversed triangular cells with walls of a single thickness, the bases of the cells forming parallel spaced faces having longitudinally extending seams, the seams being welded together, the end of said panel projecting into the laterally opening channel of the sill or plate forming member, and being secured thereto, and a wall forming panel similar to the floor or ceiling forming panel and having vertically extending cells, its end being received in the vertically opening channel.

14. A building as claimed in claim 13, wherein the horizontal wall of the sill or plate forming member is apertured to permit passage of air from the said member to the cells of the vertical panel.

15. A building as claimed in claim 13, wherein the horizontal wall of the sill or plate forming member is apertured to permit passage of air from the said member to the cells of the vertical panel, and having means in the sill or plate forming member to close oif the same so that predetermined cells in the floor or ceiling forming panel may be placed in communication with predetermined vertical cells in the wall forming panel, other cells beingcut off.

16. A building oor, wall, or the like, formed of sheet metal and having parallel faces and diagonal connecting elements, each diagonal connecting element being integral with and ya continuation of the sheet metal forming the adjacent face portion, said connecting elements forming longitudinally extending cells of triangular cross section, the'adjacent cells being reversed to form longitudinally extending seams at their apices, said seams being welded, certain of the bases of the triangular cells consisting of two pieces of sheet metal united along a longitudinal seam.

SALVATOR S. CALAFA'I'I. 

